Evaporation apparatus for high efficiency fire place or heater with humidification feature

ABSTRACT

A heater having an evaporating and humidifying apparatus therein, the evaporating and humidifying apparatus comprising a fluid pan with a heating element. In one aspect, the pan is in fluid communication with a condensate trap assembly. In one aspect the apparatus can include a base pan, the heating element, an insulator and an evaporation pan above the heating element. The evaporating and humidifying apparatus can include a fluid level sensor operatively associated with the heater controls. The condensate trap assembly may include a fluid level sensor operatively associated with the heater controls to determine fluid levels in the trap assembly. In one aspect the pan comprises an ultrasonic vaporization element in lieu of a heating element.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of provisional application Ser. No.61/619,186 filed Apr. 2, 2012, which is incorporated herein byreference.

BACKGROUND OF THE INVENTION

High efficiency fireplaces or heaters can produce significantcondensate. Various embodiments employ a tray located above the fireboxto evaporate the condensed products of combustion and humidify in thearea around the appliance. However, if a heater does not include alarge, hot firebox, there is not enough heat generated within the heateritself to evaporate all the condensate.

Also, such heaters are generally used in cold weather to heat a spacewithin a building. Often there is low humidity in the enclosed space asa result of the operation of heaters and furnaces. Low humidity canaggravate inhabitants by drying the skin and mucous membranes ofinhabitants of the heated space.

It would be advantageous, therefore, to have an efficient apparatuswithin the heater to evaporate condensation and moisture. Moreover, itwould be beneficial to use the evaporated condensate to humidify thearea around the heater.

SUMMARY OF THE INVENTION

A heater having a condensate trap and an evaporating and humidifyingapparatus, the apparatus comprising an evaporation pan with a heatingelement wherein heat from the heating element evaporates moisture fromthe evaporating pan to eliminate the moisture and generate humidity.

In another aspect, the pan comprises an ultrasonic vaporizing element tovaporize moisture collected in the pan.

The apparatus can include a sensor with a feedback to heater controls.Also the heater can include a water trap that normally feeds condensateto the apparatus. The trap can include a sensor with feedback to theheater controls.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevational view of a heater employing the apparatusof the present invention, sans cover, to show the internal components ofthe heater;

FIG. 2 is an end plan view of the heater;

FIG. 3 is an enlarged perspective view of one embodiment of a condensatetrap;

FIG. 4 is a perspective view of an assembled evaporation apparatus; and

FIG. 5 is an exploded view of an evaporation apparatus.

DETAILED DESCRIPTION

In general, the present invention employs an electric element to heatcondensate from the products of combustion for the purpose ofhumidification.

FIGS. 1 and 2 illustrates a heater, indicated generally by number 10,which employs a representative embodiment of an evaporating apparatusindicating generally by reference number 12. Apparatus 12 also can bereferred to as a humidifying apparatus, as will be understood from thedetailed description, below.

The salient components of heater 10 include an outer housing 14 whichenclose the inner working parts inside chamber 16. The working partsinclude an induced draft blower 18 that draws combustion products from aheat exchanger 24. An exhaust pipe 26 is in fluid communication with theheat exchanger and blower 18 to discharge exhaust gas. A burner housing27 houses gas burners (not seen). Flames from the gas burner enter heatexchanger 24 tubes adjacent burner housing 27. A circulating air blower28 draws in room air from the upper rear area of heater 10 across heatexchanger 24 and discharges heated air out of the lower front of theunit. Chamber 16 generally comprises sheet metal walls that define theinner chamber and shields, such as shield 29 over heat exchanger 24.

Heater 10 is operated or controlled in any acceptable way. One preferredaspect of a heater control system is disclosed in the assignee's patentapplication Ser. No. 13/770,446, filed Feb. 19, 2013, which isincorporated herein by reference

During operation, condensation occurs inside the heat exchanger tubeswhen the products of combustion are cooled below the dew point. This isa consequence of highly efficient gas heating equipment. There is acondensate collection point, indicated generally by number 30 adjacentinduced draft blower 18 to collect condensation from combustion chamber16. There is a second condensation collection point, indicated generallyby number 32, on exhaust pipe 26. It will be appreciated that the twocondensation collection points described herein are merely illustrativeof the broad aspects of the invention. One skilled in the art willappreciate that there can be one or there can be a plurality ofcollection points, optimally positioned within housing 14 to collectmoisture and condensation. The number or location of the collectionpoints is incidental.

In any event, heater 10 can include an apparatus to trap or collect thecondensate from the collection points. One aspect of such an apparatusis trap assembly 34 shown in FIG. 3. Trap assembly 34 is a container orcanister which can have a top 36, a closed bottom 38 and circumferentialwall 40 that define and inner chamber 41 that has sufficient volume toaccommodate a continuous flow of condensate from the condensatecollection points without filling up. Conduits or tubes 42 and 44 extendthrough top 36 and terminate near the bottom of the inner chamber attheir first ends and each one is in fluid communication with acondensate collection point at a second end of the tube.

There is an overflow drain 46 that extends through circumferential wall40 and is in fluid communication with the inner cavity. Drain 46 isposition on wall 40 adjacent top 36. This allows some level of fluidaccumulation within the trap before it flows out of the overflow drainto the evaporating apparatus 12, as will be explained below. Hence, theposition of the overflow drain may vary depending upon the fluid leveldesired.

Trap assembly 34 is positioned below blower 28 such that condensate willflow under force of gravity from the collection points into the chamber.The purpose of the condensate trap is to allow condensate to flow fromthe collection points even though the collection points are each atdifferent pressures. These pressures are different from the pressure atevaporation apparatus 12. Trap 34 allows condensate to flow withoutallowing flue gas to escape. Overflow drain 46 is in fluid communicationwith the upper end 48 of a condensate drain tube 50. Tube 50 extendsdownwardly and terminates in with an open end adjacent evaporatingapparatus 12. Although in a preferred aspect of the invention, draintube 50 terminates adjacent evaporating apparatus 12, it also mayterminate in a discharge to or drain outside housing 14 to dispose ofcondensate.

Nevertheless, it will be understood that condensation is collected fromthe condensation points 30 and 32 and flows into trap assembly 34. Whenthe fluid level reaches a predetermined level, i.e. at the level ofoverflow drain 46, it will flow out, through the upper end 48 of draintube 50. In a preferred aspect it drains into evaporating apparatus 12.The location and configuration of the trap, the tubing and thecondensation collection points can vary between heaters. The salientprinciple is that the heater may include apparatus to collectcondensation and transport the condensate to the novel evaporatingapparatus 12.

Trap assembly 34 can include a sensor, indicated generally by referencenumber 51. Sensor 51 can be any type of acceptable sensor, such as afloat, electric eye, electrical connection switch. It will be noted thatsensor 51 can be located within the canister or outside, depending uponthe type. Regardless of the type of sensor employed, sensor 51 isconfigured to detect an excess accumulation of water in the trap, whichcould indicate a blocked drain or other impediment to fluid flow. Sensor51 can be operatively connected to the heater controls so that detectionof a critical fluid accumulation would shut down the heater to preventoverflow of condensate. Also, it can be operatively connected to theevaporating apparatus to shut down the evaporating heating element, aswill be explained.

Evaporating apparatus 12 is shown in detail in FIGS. 4 and 5. In theexemplary embodiment, apparatus 12 includes a bottom pan 52 which, inthe illustrated embodiment, has a generally rectangular shape. It willbe understood that apparatus 12 can have any useful configuration thatworks well in the intended environment. Pan 52 includes a bottom wall54, a first end wall 56 with holes 58 and 60, a second end wall 62 andfirst side wall 64 and a second side wall 66. The recited walls definean inner cavity 68. In one aspect, an insulative sheet 70 may bepositioned in the cavity on bottom wall 54. Insulative sheet 70 can beconstructed from any acceptable insulative material. Furthermore, topsurface 72 of the insulative sheet can be heat reflective.

Apparatus 12 includes a vaporization element. In one aspect, thevaporization element is an electric heating element 74 is positioned incavity 64. If the apparatus includes an insulative sheet, heatingelement 74 is positioned above the insulative sheet. Heating element 74can be any conventional heating element with electrical connections 76and 78 that protrude through holes 58 and 60 and are connected toelectricity. In one aspect, an evaporating pan 80 is positioned on topof heating element 74 and under the open end of tube 50. Pan 80 has abottom wall 82, a first end wall 84, a second end wall 85, a first sidewall 86 and an opposed second side wall 88. The recited walls and bottomdefine an inner cavity 90. It will be noted that the configuration ofpan 80 is complementary to that of bottom pan 52 and sized so as to nestin the bottom pan. In other aspects or embodiments of the invention,there can be a layer of metal (not shown) between insulative sheet 70and heating element 74. The size and configuration of the variouscomponents of the evaporating apparatus may vary without departing fromthe scope of the invention.

Also, it will be recognized by one skilled in the art that theevaporation apparatus can comprise only one pan, with a heating elementoperatively associated with the pan. By way of example, heating element74 can be positioned inside an evaporation pan or outside, for example,under the pan. Moreover, the heating element can be integrated into thepan itself, for example, with heating wires within the pan material. Inthe appropriate circumstances, the heating element could be a gas flame,rather than an electric heating element. Hence, the term heating elementcan encompass any apparatus that heats moisture to evaporate or vaporizethe moisture.

Furthermore, although the exemplary embodiments refer to pans forsimplicity and convenience, it will be understood that any type of fluidreservoir that can collect and hold fluid such as condensate is withinthe scope of the invention.

In operation, there can be a sensor 92 associated with evaporating pan80 to sense an accumulation of liquid in the pan. A feedback loop canactuate a switch to turn on heating element 74. In other aspects, atemperature sensor may be employed to sense when the condensate hasboiled and can include a feedback loop to de-energize or shut off theheating element.

The heat from the heating element causes evaporation of the liquid inpan 80. Consequently, condensate from the operation of heater 10 isdissipated through evaporation. Sensor 92 (or another sensor) can beused to determine if the fluid level in the patent exceeds apredetermined level and shut down the heater to prevent further fluidaccumulation. Sensor 92 can be any appropriate sensor that serves itsintended purposes, such as the sensors described above relative to trapassembly 3 and can be located in or on, or associated with any of theevaporation apparatus components.

As set out above, heating element 74 can be operatively associated withsensor 51 of the trap assembly. If there is an increase in fluid in thetrap, it could indicate that fluid is not flowing to the evaporationapparatus and the sensor could shut down the heating element or theentire heater.

In another aspect or evaporation apparatus 12, the vaporization elementmay be an ultrasonic vaporization device 94 in the pan, as shown in FIG.5. An ultrasonic vaporization device uses a metal diaphragm vibrating atan ultrasonic frequency, much like the element in a high-frequencyspeaker, to create water droplets. An ultrasonic vaporization device isusually silent, and also produces a cool fog.

It will be appreciated that evaporated or vaporized liquid serves as asource of humidity for the space where the heater is located. As shown,evaporating apparatus 12 is located adjacent the bottom of heater 10,below heat exchanger 24 and blower 28. This arrangement permits airforced downward by the blower across the heat exchanger to pick upmoisture from apparatus 12 and expel it into a room from the bottomfront of the heater. However, other locations of apparatus 12 thataccomplish the desired purposes are intended to be included in the broaddisclosure.

Heater 10 can include sensors and switches that allow the heatingelement or ultrasonic vaporizer to be actuated only when blower 28 isoperating so vapor from the condensate is introduced into room airrather than building up in the heater. The heater with the evaporatingapparatus 12 serves the dual function of providing heat and humidity.

The evaporation or vaporization feature of the heater may be employed inany heater that produces moisture in operation and has means forcollecting the moisture and diverting it to the evaporation andvaporization elements.

The foregoing description and accompanying drawings are intended to beillustrative of exemplary embodiments of the heater only and should notbe construed in any manner that limits the scope of the appended claims.

1. A heater comprising; a control system for controlling the operationof the heater; a burner; a heat exchanger in communication with theburner; a blower; a condensate trap assembly; and a humidifyingapparatus comprising an evaporation pan in fluid connection with thecondensate trap assembly, said pan associated with a vaporizationelement wherein the vaporization element vaporizes moisture from theevaporation pan to generate humidity.
 2. The heater of claim 1 whereinthe vaporization element is a heating element.
 3. The heater of claim 1wherein the vaporization element is an ultrasonic vaporization device.4. The heater of claim 1 wherein the humidifying apparatus is below theheat exchanger.
 5. The heater of claim 1 wherein the evaporation pancomprises a fluid sensor.
 6. The heater of claim 5 wherein theevaporation pan fluid sensor is operatively associated with thevaporization element.
 7. The heater of claim 5 wherein the evaporationpan fluid sensor is operatively associated with the control system. 8.The heater of claim 1 wherein the evaporation pan further comprises aninsulative sheet.
 9. The heater of claim 1 wherein the condensate trapassembly includes a fluid sensor.
 10. The heater of claim 9 wherein thecondensate trap assembly fluid sensor is operatively associated with thecontrol system.
 11. The heater of claim 9 wherein the condensate trapassembly fluid sensor is operatively associated the vaporizationelement.
 12. The heater of claim 1 wherein the evaporation pan furthercomprises an insulative sheet.
 13. The heater of claim 2 wherein theheating element is an electric heating element.
 14. A heater comprising;a control system for controlling the operation of the heater; a burnerand associated heat exchanger; a blower; a condensate trap assembly; anda vaporizing apparatus below the blower, the vaporizing apparatuscomprising a fluid reservoir with a vaporization element disposed tovaporize fluid in the fluid reservoir.
 15. The heater of claim 14wherein fluid reservoir comprises a fluid sensor.
 16. The heater ofclaim 14 wherein the vaporization element is a heating element.
 17. Theheater of claim 14 wherein the vaporization element is an ultrasonicvaporization device.
 18. The heater of claim 15 wherein fluid reservoirfluid sensor is operatively associated with the control system.
 19. Theheater of claim 11 wherein the condensate trap assembly includes a fluidlevel sensor.
 20. The heater of claim 15 wherein the condensate trapassembly fluid level sensor is operatively associated with the controlsystem.